Subject Code : MET 352

Sub name:
AUTOMOBILE ENGINEERING

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 1
Department,Govt.Engineering College,
What is Automobile engineering?
 An applied science
 Mechanical engineering, Electrical engineering, Electronic
Engineering, Software Engineering and Safety engineering

From where this name comes?

Ancient Greek word autos, means "self " and the Latin word
mobiles means "movable".

What is an Automobile?
self propelled vehicle that travels on land
an engine provides the power to move it
it is used for transportation of passengers and goods

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 2
Department,Govt.Engineering College,
 Classification of Automobiles
There is a wide range of automobiles designed for specific duties.
 The two-wheeler mopeds, scooters, motor-cycle are used by individuals
Four-wheeler cars and jeeps are family vehicles
 Vans (minibus) and buses serve the society by transporting people,
 Trucks are required for carrying goods,
Tractors are field vehicles, bulldozers are used in construction work and gun-
carriage is involved in military operations.

1. Application.
2. Make, and model
3. capacity
4. Fuel used
5. Engine layout
6. Transmission
7. Steering
8. Suspension
9. Wheels and axles
10. Body and number of doors.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 3
Department,Govt.Engineering College,
Scooters
Bikes.
Cars
Buses.
Trucks
1.Application 2. Capacity
 Auto cycles and Mopeds Heavy Transportation vehicles (H.T.C.) or
 Scooters and Motor Cycles Heavy Motor Vehicles : Buses, Coaches,
 Cars, vans, jeeps, station Trucks, Tractors.
wagons and pick-ups Light Transportation Vehicles (L.T.V.) or
 Buses (lorries)and trucks Light Motor Vehicles : Cars, Jeeps, Scooters,
 Tractors , Bulldozers motor cycles, Mopeds, Vans.
Medium Transportation Vehicles (M.T.V.)
or Medium Motor Vehicles: Tempo, Minibus,
Pick-ups, Station Wagons.

3. Make and Model

Trucks and Buses : Leyland, Tata, Nissan, Shaktiman, Dodge, Bedford.
Cars : Ambassador, Standard Herald, Fiat (Premier, President), Maruti 800, Tata
Indica, Hyundai Santro, daewoo Matiz, ford Escort, Opel Astra.
Scooters & Motor Cycles : Vespa/Bajaj, Lambretta, Raj Hans, Rajdoot, Royal
Enfield, Hero Honda.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 9
Department,Govt.Engineering College,
4. Fuel used 5.Engine Layout
Petrol or gasoline Engine : 5.1 Basic Engines
Diesel Engines Internal Combustion Engines : Spark
Gases: Liquefied Petroleum gas Ignition Reciprocating
(LPG) or Compressed Natural Compression Ignition.
gas (CNG).  Gas Turbine Engine
Electric, Hybrid and fuel cell  Wankel engine.
engines:.  Batteries and Fuel Cells: Stationary
source of power for future vehicles.

5.2Number of Engine Cylinders

 Single Cylinder engines are used for
scooters, motor cycles, mopeds.
 Three or four cylinder engines are used
for small cars.
 Multicylinder engines
 The engines may be placed horizontally
(air-cooled motor cycles); vertically
(water cooled engines for cars, jeeps,
buses, trucks

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 10
Department,Govt.Engineering College,
 7. Steering or Drive
7.1 The position of the drive in the vehicle.
(a)Left hand drive
6.Transmission (b)Right hand drive
 Manual transmission or
conventional transmission. 7.2 The engine is connected to the driving axle.
 Semi-automatic type British (a)Front wheel drive: The engine transmits
vehicles are equipped with power to the front wheel.
semi-automatic transmission. (b)Rear wheel drive: The engine supplies
 Automatic Transmission: power to the rear wheel
 CVT and AMT (c)All wheel drive : The engine transmits
power to all the four wheels and engine can be
placed in front or rear of the vehicle. Examples
are Jeeps, willey’s Jeep 4 X 4 Nissan 4 X 4.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 11
Department,Govt.Engineering College,
8. Suspension
The type of springs or cushions used between wheels and chassis.
1.Conventional : Leaf springs are attached to a rigid beam axle.
2.Independent system : Coil sprints, torsion bar or pneumatic shock absorbers are
attached to each wheel to ensure its dependent vertical movement without any reaction
on the other wheels.

9. Wheels and Axles

9.1 wheels
Two wheelers, e.g., scooters, motor cycles, mopeds.
Three wheelers, e.g., tempos, autorikshaws.
Four wheelers, e.g., cars, jeeps, vans, buses, trucks (6 tyres)
Six wheelers (10 tyres): Shaktiman and Dodge.
9.2 Axles:
 Dead axles of the vehicle do not rotate and wheels rotate such as horse drawn
wagon.
Live axles are attached to the wheel and both rotate together

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 12
Department,Govt.Engineering College,
10.Bodies and Number of Doors
Closed doors such as saloons, coupe, etc.
Open cars like sports car, convertible cars, etc.
Special styles such as estate car, station wagon, etc.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 13
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 14
Department,Govt.Engineering College,
 Layout of Chassis

Chassis
 A vehicle arrangement
without body is called chassis
(Chassis =Automobile-Body)
 It contains all the
major units necessary to
propel the vehicle, direct its
motion, stop it and allow it to
run over uneven surfaces.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 15
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 16
Department,Govt.Engineering College,
It consists of
(i) The frame
(ii) The engine
(iii) The transmission system
(iv) The wheels and tyre assembly
(v) The suspension system
(vi) The steering system
(vii) The fuel tank and fuel supply
systems
(viii) The electrical system
(ix) The brake system
(x) The engine cooling system
(xi) The auxiliaries

Frame
It is rigid structure that forms a Skelton to hold all the major
units together.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 17
Department,Govt.Engineering College,
Classification of chassis
1. According to its control
1.1 Conventional chassis
-Engine fitted in front of the driver seat
- Slopes are provided in the bonnet and mudguard
-- Portion of the chassis where engine is fitted cannot be utilized
to carry passengers or goods

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 18
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 19
Department,Govt.Engineering College,
1.2 Semi forward chassis

-Half of the portion of the engine in drivers cabin

- Part of the chassis utilized to carry passengers and goods

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 20
Department,Govt.Engineering College,
1.3 Full forward chassis

-In this type of chassis complete engine is mounted inside the driver
cabin
- Increased floor area

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 21
Department,Govt.Engineering College,
2.According to fitting of the engine

2.1 Engine at front

2.2 Engine fitted at front but cross ware
2.3 Engine fitted at the centre of the chassis
2.4 Engine fitted at back side

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 22
Department,Govt.Engineering College,
 Frame
• Main skeleton of the vehicle
• It serves as the main foundation and base for alignment for the
chassis
• Front end of the frame carries the engine while rear end carries
rear axle housing wheels and tyres
• Frame is provided with cross links to increase the rigidity ,with
stand shocks and vibrations

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 23
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 24
Department,Govt.Engineering College,
Types of frames

1.Conventional frame
2.Semi integral frame
3.Integral or Unitied frame

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 25
Department,Govt.Engineering College,
1. Conventional frame
- Also known as non load carrying frame
- Load on the vehicle is transferred to the suspension system by
the frame ,which support the engine ,power train and the
body
- Body is made of wood and completely isolated from the frame
deflection with the help of rubber mountings
- This type of frame not much suited to resist torsion
- Use of tubular or box – section back tone type of frame
improves the torsional strength

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 26
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 27
Department,Govt.Engineering College,
2. Semi integral frame
•In this arrangement the rubber body mounts are replaced by
relatively stiff mounts so that a part of frame load is transferred
to the body structure
•This frame is heavy

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 28
Department,Govt.Engineering College,
3. Integral or unitied frame or Frameless construction
• No frame and all the assembly units are attached to the body
• The chassis and the body are assembled by welding from a
large number of mild steel pressingings
• This design reduced vehicle weight, lowers production cost and
allows lower floor

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 29
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 30
Department,Govt.Engineering College,
Transmission System
Includes
- Flywheel
Transmission system is a - Clutch
group of mechanisms work - Gear Box
together , which transmit - Propeller Shaft
power from engine to wheels -Universal Joint
- Differential
- Rear Axle
- Wheels and Tyres
Clutch Types of Clutches
- It is a mechanism 1. Friction Clutches
- Which transmit power from 2.Fluid Coupling
one rotating shaft to
other when it desired

Tennison K Jose, Assistant Professor, Department of Mechanical

5/24/2022 Engineering,Govt.Engineering College Thrissur 32
Requirements of a Good Clutch
1. Torque Transmission
2. Gradual Engagement
3. Good Heat Dissipation
4. Compact Size
5. Sufficient Clutch Pedal Free Play
6. Ease of Operation

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 33
Department,Govt.Engineering College,
Friction clutch
A friction clutch is a clutch in which the drive is transmitted by the
friction between surfaces attached to the driving and driven shafts.
These surfaces are lined with cork, asbestos, or other fibrous
material.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 34
Department,Govt.Engineering College,
Friction Clutches
Classified into
1.Single plate clutches
2.Multiplate Clutches
3.Centrifugel Clutches

Tennison K Jose,Assistant
Professor,Department of Mechanical
5/24/2022 35
Engineering,Govt.Engineering College
 Single plate clutch

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 36
Department,Govt.Engineering College,
Single plate clutch contains
1.Flywheel
2. Clutch plate / Disc plate
3. Pressure Plate
4. Clutch cover assembly
5.Release mechanism
6.Withdrawl force and
rearing
7. Primary of Clutch shaft

Tennison K Jose,Assistant
Professor,Department of Mechanical
5/24/2022 37
Engineering,Govt.Engineering College
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 38
Department,Govt.Engineering College,
 Construction
 Friction plate is held
between flywheel and
pressure plate
 Springs provide for axial
force which keep clutch in
engaged position
 Friction plate is mounted on
a hub which is internally
splined so free to move
Friction facing is attached to
friction plate on both sides
 A pedal is provided to pull
the pressure plate against
spring force

Tennison K Jose,Assistant
Professor,Department of Mechanical
5/24/2022 39
Engineering,Govt.Engineering College
 Working
• The clutch plate is kept between flywheel and pressure plate by number
of pressure springs
• Due to the friction between the flywheel ,clutch plate and pressure plate
,the clutch plate revolves with the flywheel
• The clutch plate rotation, revolves the clutch shaft
• The clutch shaft is connected to the gear box
• when pedal is operated ,pressure plate is moved back against spring
forces
• This movement of pressure plate releases friction plate and clutch
become disengaging position
• The gap between the pressure plate and flywheel increases
Tennison K Jose,Assistant
Professor,Department of Mechanical
5/24/2022 40
Engineering,Govt.Engineering College
• The clutch pedal release enable the pressure plate spring to come
back to its original position (Spring release position)
• The pressure plate is moved towards the friction disc and press it
against the flywheel
• This is called clutch engaging

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 41
Department,Govt.Engineering College,
Multiplate clutches
- It is an extension of single plate clutches
- No of frictional plates are increased
- Clutch size can be reduced for same torque
-Used in racing cars , two wheelers etc.
-The total number of clutch plates divides into two sets in which one
from each set is alternatively arranges.
-One set of the plate slides in grooves on the flywheel and the other
one slides on splines on the pressure plate hub. These plates are
reliably pressed by a strong coil spring and assembled in a drum.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 42
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 43
Department,Govt.Engineering College,
Fully automatic Centrifugal clutches
 This clutch is controlled by the engine speed
 The clutch is disengaged when engine speed is falls down
 The clutch is engaged when the engine speed rise above pre
determined value
 Higher engine speed create higher centrifugal force
- Spring are eliminated
- Advantage is that no separate pedal is required

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 44
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 45
Department,Govt.Engineering College,
Constructional features
• It consists of two members- one fitted on the driving shaft and the
other attached to the driven shaft
• The driven member is a drum which encloses the driving member
• The driving member consists of a spider , shoe having friction
lining at the outer end and spring
• The shoes are attached to the spider by means of spring
• The springs exerted radially inward force which is assumed
constant

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 46
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 47
Department,Govt.Engineering College,
Centrifugal clutch working
• The driving member rotates with the engine shaft.
• As the engine speed increases the shoes inside the driving member
drum will fly outward due to the centrifugal force and come into
contact with the inner surface of the driving member
• The increasing centrifugal force due to the higher speed binds the
driving member with the driven member resulting in the
movement of both the member and the shafts at the same speed
• The magnitude of the centrifugal force depends on the speed at
which shoe is revolving

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 48
Department,Govt.Engineering College,
• When the engine speed decrease the centrifugal force will
decrease which results the disengagement of the clutch
• The force with which the shoe presses against the driven member
is the difference between the centrifugal force and spring force

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 49
Department,Govt.Engineering College,
Semi centrifugal clutch

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 50
Department,Govt.Engineering College,
Constructional features

• Similar to centrifugal clutches

• Disadvantages of centrifugal clutch are
Automatically disengaging at low engine speeds
 Only at high speeds, centrifugal force is sufficient to keep the
clutch in engaged position
• Pressure spring used to exert pressure at low and idling speeds
• Springs are designed to transmit the torque at lower engine
speeds
• Centrifugal force assists in torque transmission at higher engine
speeds
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 51
Department,Govt.Engineering College,
Constructional features

• Three hinged and weighted levers and three clutch springs

alternately arranged at equal space on the pressure plate(only
one lever and clutch spring shown in figure)
• Fly wheel is fitted to engine crank shaft
• Clutch plate is mounted on the splines of the clutch shaft
• Pressure plate is freely supported on clutch shaft

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 52
Department,Govt.Engineering College,
Working of semi centrifugal clutch

• Clutch engagement
 Clutch springs exerts pressure on pressure plate at low
engine speeds
 At high speeds the centrifugal force developed by rotation of
weighted levers exerts pressure on pressure plate
• Pressure plate applies pressure on clutch plate
• Clutch plate firmly rotates in between fly wheel and pressure
plate
• Clutch shaft rotates along with clutch plate

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 53
Department,Govt.Engineering College,
Clutch disengagement
• As Driver presses the clutch pedal, pressure plate moves back
against the force of the springs
• Clutch plate also moves back on splines of clutch shaft
• Clutch plate speed reduces slowly and finally stops

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 54
Department,Govt.Engineering College,
Electromagnetic clutch
• An electromagnetic clutch is also a friction clutch but it uses
magnetic force in place of spring force to engage and disengage
the clutch.
• Electromagnetic clutches operate electrically but transmit torque
mechanically.
• This is why they used to be referred to as electro-mechanical
clutches.
• There is also a friction plate between them.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 55
Department,Govt.Engineering College,
• The magnetic field apply force to connect both these plates and
friction plate transmit torque between them.
• Thus this clutch is combination of both electromagnetic effect
and mechanical clutch.
• This type of clutch is employed in some Renault cars.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 56
Department,Govt.Engineering College,
Constructional Features and working

• The engine flywheel is incorporating

with winding
• Windings is connected to the engine
dynamo
• Clutch plate is lined with friction
materials and is free to slide on
splines on the clutch shaft.
• There is a clutch release switch in
the gear lever

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 57
Department,Govt.Engineering College,
• Springs are provided in the clutch to balance the reduced
electromagnetic force
• During normal operation the electromagnetic force of the winding
is regulated by means of electrical resistance ,which itself is
controlled by the accelerator pedal
• As the accelerator pedal is pressed the resistance is gradually
reduced thus increasing the electromagnetic force

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 58
Department,Govt.Engineering College,
•When winding B is
energized ,it attracts the
pressure plate D,thereby
engaging the clutch
•When supply to the
winding is cut off, the
clutch is disengaged

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 59
Department,Govt.Engineering College,
Clutch materials
Common materials are
1.Leather
Dry leather or iron
2.Cork
Cork on dry steel or iron
3.Fabric
4. Asbestos
5. Reybestos and Ferodo
6.Non asbestos clutch facing
Made from man made yarns such as glass fibre,mixed with special
rubber compound to improve frictional perfromance ,firmly locked
with elastomers-based novalac binder and moulded with pressure
and heat
7.Graphite material for higher operating applications
Sintered metal friction material- Made by combining metalloic
powders and friction modifiers and, Asst.Professor
Tennison K.Jose compacting them into solid
,Mechanical Engineering
5/24/2022 60
form Department,Govt.Engineering College,
There are Three types of friction materials
1.WOVEN TYPE
2.MOULDED OR COMPRESSION TYPE
3.MILL BOARD TYPE
WOVEN TYPE
This is made by spinning threads from asbestos fibers, sometime
brass wires ,weaving this thread into a cloth and then impregnating
it with a bonding material

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 61
Department,Govt.Engineering College,
2. The moulded or compression type
• The lining is composed of asbestos fibers in
their natural state mixed with binding
material and then moulded in dies under
pressure and at elevated temperatures .
• Metallic wire are sometimes included but
only to increase the wearing qualities and
to eliminate scoring of the metal faces
against which the lining rubs

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 62
Department,Govt.Engineering College,
3.Mill board type

• In this type friction materials mainly included asbestos sheets

treated with different type of impingements
• From this sheets the facing disc cut according to different sizes

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 63
Department,Govt.Engineering College,
Wet clutch
• The constructional features are similar to dry friction plate, except
that here the clutch plates are always wetted by oil circulation.
• Here different types of friction materials are used and the
construction is different from dry plate clutch
• The oil is sprayed through the holes in the clutch plate by a nozzle
• This type of clutches are suitable only for small trucks where
sufficient torque can obtained from a single plate clutch, since the
value of coefficient of friction decreases due to the presence of oil
on the friction surface

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 64
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 65
Department,Govt.Engineering College,
• A multiple wet clutch consists of a number of thin plates made of
steel fitted to the engine shaft and those on the gear shaft are
made of phosphor bronze.
• These plates are immersed in a bath of oil and also have grooved
surfaces for permitting the oil to flow through them.
• These grooves help to dissipate the heat generated during the
engagement and release operations.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 66
Department,Govt.Engineering College,
 Gear Box
Classified into
1.Sliding Mesh gear box
2.Constant Mesh gear box
3.Synchromesh gear box
Sliding mesh gear box
- Simple
- clutch shaft, clutch gear
and lay shaft
- Gears in lay shaft are fixed
- Gears on main shaft can
slide over the main shaft

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 67
Department,Govt.Engineering College,
Constant Mesh Gear Box
- The gears are in constant mesh with
corresponding gears on lay shaft
- Main shaft is splined so that gears can
move forward and backward
-Dog clutches are provided (A dog clutch
couples two rotating shafts or other rotating
components not by friction, but by interference.
Both the parts of the clutch are designed so that
one pushes into the other, causing both to
rotate at the same speed, so that they never

slip.)

- It can freely move on the main shaft

Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 68
Department,Govt.Engineering College,
• In the constant mesh gear box all the gears mesh with each other,
all the time and this gives a silent or quiet operation.
• Gear changing is made easier by employing helical gears.
• The primary shaft which carries the clutch is splined and carries a
gear that meshes with the largest lay shaft gear
• The main shaft has a number of gears that mesh with the gears on
the lay shaft. However, these gears being on bushes or ball/roller
bearings are free to move on the main shaft without transmitting
any torque.
• All the gears on the lay shaft are rigidly fixed with it.
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 69
Department,Govt.Engineering College,
Working
• When the left-hand dog clutch is made to slide to the left by means
of the gearshift lever, it meshes with the clutch gear and the top
speed gear is obtained.
• When the dog clutch meshes with the second gear the second
speed gear is obtained.
• Similarly by sliding the right-hand dog clutch to the left and right,
the first speed gear and reverse gear are obtained respectively.
However, skillful handling is necessary on the part of the driver so
that the speed of the locking dogs and respective pinion remain
the same to effect a clash-free gear change.
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 70
Department,Govt.Engineering College,
• For the smooth engagement of dog clutches, it is required that
the speed of main shaft gears and the dog clutch must be
equal.
• The shifting of gears was not at all an easy task and only a
skilled driver can drive such a vehicle and the special
technique required was Double-declutching.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 71
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 72
Department,Govt.Engineering College,
Synchromesh Gear Box
- Similar that of Constant mesh gear box
- Gears on the main shat is constant mesh with gears of lay
shaft
- Main shaft gears are free to rotate
-Main shaft gears and lay shaft gears are always rotating
-in Synchromesh gearbox, Instead of Dog clutch, Synchronizer Ring
and Hub is used.
-Synchronizer Ring helps in bring the all shaft speed to equal and
Synchronizer Hub helps in smoothly engage the gears.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 73
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 74
Department,Govt.Engineering College,
1. Engine Shaft
2. Lay Shaft
3. Output Shaft
4. Gears on Lay shaft
5. Gears on Output shaft
6. Cone
7. Synchronizer Hub
8. Sliding Sleeve
9. Synchronizer Ring

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 75
Department,Govt.Engineering College,
1. Engine Shaft:- Engine Shaft’s one end is connected to the clutch,
hence when the clutch engages, the engine shaft rotates at the speed
received from the engine.
On the other end of the engine shaft, the clutch gear is fixed.
Clutch gear constantly meshes with the lay shaft gear. Hence when the
clutch is engaged, power transmission occurs from the engine shaft to
the lay shaft.
2. Lay Shaft:- There are 5 fixed gears located on the lay shaft are gear1,
gear2, gear3, gear4, gear5.The Gear 5 is located on lay shaft meshes
with clutch gear which rotates with power from the engine shaft.

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3.Output Shaft:- There are 4 Gears on this shaft.
4.Gears on Lay shaft:- There are four gears fixed on the lay shaft.
These gears are constantly meshing with the gears on the output
shaft.Hence power transmission occurs from the engine shaft to the
gears on output shaft gears through the gears on lay shaft.
5.Gears on Output shaft:- These gears are located on the output
shaft which are freely rotated on it.
Externally Cone shape cones are attached to the gears. Cones have
Dog teeth for the Gear engagements. When the driver shifts the
gear, through the shift fork, Sliding sleeve press the Synchronizer
Ring on the cone.
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6. Cone:- It is an external cone shape part that is attached to the
gears. Cones have Dog teeth for the Gear engagements.
As per movement of shift fork, sliding sleeve (having internal teeth)
slides & internally meshes with the dog teeth of the cone.
7. Synchronizer Hub:- Synchronizer hub is fixed on the output shaft.
It has external teeth for the sliding of the sleeve.
Sliding Sleeve is internally meshing with the Synchronizer hub. Hence
sliding sleeve can slide in both directions.
8.Sliding Sleeve:- Sliding Sleeve is internally meshing with the
Synchronizer Hub. Hence sliding sleeve can slide in both directions.

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It is used for the interlocking of Synchronizer Hub and Cone.
The gear lever is connected to the shift fork & the shift fork is
connected to the sliding sleeve.
Hence when the driver shifts the gear, the shift fork moves the
sleeve on the hub.
8.Synchronizer Ring:- Synchronizer Ring has an internal cone shape
to engage with the cone. When Driver shifts the gear, the shift fork
moves the sleeve, therefore the sleeve Presses the Synchronizer Ring
inside the cone.

Tennison K.Jose , Asst.Professor

,Mechanical Engineering
5/24/2022 79
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
5/24/2022 80
Department,Govt.Engineering College,
 Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
Epicyclic gear Box
This type of gear box uses no sliding dog or gears to engage but
different gear speeds are obtained by merely tighten brake bands
on the gear drums

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Constructional features
It consist of
a) Ring gear annual wheel
b) Sun gear
c) Planet gears with carrier
• The ring gear contains teeth on it inner
circumferences and is surrounded by a
brake band
• The brake band is operated by a gear stick
or lever to grip the ring gear and hold its
movement
• The sun gear is rotated by driving shaft
from the engine
• The planet gears are in constant mesh
with both the sun gear and ring gear and
are free to rotate on their axes carried by
Epicyclic gear set
the carrier frame which in turn is
connected to the driven shaft

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Working
•When the ring gear is locked by the brake band the rotating sun gear causes
the planet gears to rotate
•Since the ring gear cannot move the planet gears are forced to climb over it.
•During this position the ring gear acts as track for the planet gears to move
over
•The driven shaft which is connected to the planet gear carrier is thus
rotated
•When the ring gear is released it is free to move in consequences to the
rotation of planet gears which rotate around their axis.
•During this position there is no movement of planet carriers and hence
shaft remains stationary
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A planetary gear box contains a number of such units to obtain
various speed reductions

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 Over drives

•The device that is used to increase the speed of the wheel greater than
the engine speed which is placed in between the Transmission system
and the Propeller shaft

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 Constructional features
It has an Epicyclic gear train
 Sun gear is free to rotate on the input shaft
 Carries can move on splines on the input shaft
 Free wheel clutch/ free wheel fitted on the input shaft splines
(allow only one directional power transmission)
 Ring gear connected to the output shaft

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Working
• The sun gear is freely rotating on the input shaft.
• When it is locked the power transmit from the input shaft to the
planetary gear and to the casing
• This will increase the speed in out put shaft
• When the sun gear is disengaged the power does not transmit to the
output shaft and the input shaft and output shaft has same speed

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